Muffler diffuser

ABSTRACT

An improved muffler diffuser insert adapted to be used with, and mounted within, an exhaust muffler for effectively helping to reduce noise and back pressure attendant to engine operation. The diffuser comprises a cap end for abutting against an exhaust end of the muffler when the muffler diffuser is mounted within the muffler, which has at least one exhaust opening defined therein for cooperation with the exhaust end of the muffler so as to permit an exhaust flow from the exhaust end of the muffler to pass through. A body portion is connected to the cap end, and defines therein an elongated opening for permitting the exhaust flow from the muffler to pass through. A distal end of the body portion comprises an outermost end and two sound deflection portions positioned on either side of the outermost end for use in deflecting sound waves contained in the exhaust flow so as to enhance noise diffusion.

BACKGROUND Related Application

This application claims priority to Canadian Patent Application No. 2,545,971, filed on May 9, 2006, the contents of which are incorporated herein by reference in their entirety for all purposes.

FIELD OF THE INVENTION

This invention relates to an improved muffler diffuser insert adapted to be used with an exhaust system for effectively helping to reduce noise and back pressure attendant to engine operation, and, more particularly, an improved muffler diffuser insert which is virtually free-flowing, causes little to no back pressure, but which will not restrict an exhaust air flow.

DESCRIPTION OF THE PRIOR ART

In 2000, for example, motorcycle manufacturers designed and built a four stroke race motorcycle for off-road use. The reason for them to do this was to counteract the growing concerns that the engines of previous models of 2-stroke bikes were causing harm to our environment. In a 2-stroke motor, it is the mixture of gas and oil that is burned in the combustion chamber and then exhausted into our air that creates an environmental issue. The 4-stroke motor is essentially an 89 Octane level of pump fuel that is used to create horsepower, and are more environmentally friendly. On the platform of this newly designed motor, however, manufacturers needed to increase the engine compression, which also increased the amount of noise that such engines produce. In the early generations of the 4-stroke motors, the decibel reading was well over 100 dB's when the engine was idling. To make these motors perform to their maximum potential, what was required was to design an exhaust system that was virtually free-flowing, causing no back pressure on the engine. If the muffler caused additional back pressure it would result in various complications—i.e.: reduction of horsepower, lack of power, overheating and premature valve failure.

In trying to address this matter, some manufacturers designed a simple solution, which consisted of using an aluminum muffler with a heat restricted material to help quiet the motorcycle down while maintaining its performance. This in turn opened up the door and presented many great opportunities for aftermarket exhaust manufacturers to create additional mufflers, pipes and muffler inserts to further enhance the performance of these machines. However, some conventional muffler inserts, during use, do not adequately allow for sufficient exhaust flow, thus “plugging up” the muffler and causing back pressure to build, and overheating of the muffler to occur to a certain degree. Thus, there is a further need for an improved muffler diffuser insert that fits into a factory or aftermarket muffler, and which will not restrict the exhaust air flow unnecessarily, but also lower the decibels of the noise produced by the engine below an acceptable level. In this regard, the present invention substantially fulfills this need.

SUMMARY OF THE INVENTION

Accordingly, one object of the present invention is to provide an improved muffler diffuser insert designed for insertion into factory or aftermarket mufflers, and that is universal to various manufacturers of mufflers.

Another object of the present invention is to provide an improved muffler diffuser insert which not only allows engine exhaust gases freely, but also lowers the decibels of the noise produced below an acceptable level, by deflecting the sound waves out of an exhaust flow and directing them instead into the packing of the muffler.

A still further object of the present invention is to provide an improved muffler diffuser insert that fits into a factory or aftermarket muffler without “plugging up” the muffler and causing back pressure and overheating of the muffler to build.

According to one aspect of the present invention, there is provided a muffler diffuser adapted to be used with, and mountable within, a muffler comprising a cap end having at least one exhaust opening defined therein, the cap end abutting an exhaust end of the muffler when the muffler diffuser is mounted within the muffler; a body portion connected to the cap end, the body portion defining therein an opening for permitting an exhaust flow from the muffler to pass therethough, and having at least one sound deflection portion for use in deflecting sound waves contained in the exhaust flow back into the muffler; and means for securing the muffler diffuser within the muffler.

According to another aspect of the present invention, there is provided a muffler diffuser adapted to be used with and mountable within a muffler comprising a cap end abutting against an exhaust end of the muffler when the muffler diffuser is mounted within the muffler, the cap end having at least one exhaust opening defined therein for cooperation with the exhaust end of the muffler, so as to permit an exhaust flow from the exhaust end of the muffler to pass through; a body portion connected to the cap end, the body portion defining therein an elongated opening for permitting the exhaust flow from the muffler to pass through, and having at least one sound deflection portion for use in deflecting sound waves contained in the exhaust flow so as to enhance noise diffusion; and means for securing the muffler diffuser within the muffler.

According to yet another aspect of the present invention, there is provided a muffler diffuser adapted to be used with and mountable within a muffler comprising a cap end abutting against an exhaust end of the muffler when the muffler diffuser is mounted within the muffler, the cap end having at least one exhaust opening defined therein for cooperation with the exhaust end of the muffler, so as to permit an exhaust flow from the exhaust end of the muffler to pass through; a body portion connected to the cap end, the body portion having a distal end portion which comprises an outermost end and two sound deflection portions positioned on either side of the outermost end for use in deflecting sound waves contained in the exhaust flow so as to enhance noise diffusion, the body portion also defining therein an elongated opening which is greater than three times a diameter of the at least one exhaust opening for permitting the exhaust flow from the muffler to pass through; and means for securing the muffler diffuser within the muffler.

The advantage of the present invention is that it provides an improved muffler diffuser insert designed for insertion into factory or aftermarket mufflers, and that is universal to various manufacturers of mufflers.

A further advantage of the present invention is that it provides an improved muffler diffuser insert which not only allows engine exhaust gases freely, but also lowers the decibels of the noise produced below an acceptable level.

Yet another advantage of the present invention is that it provides an improved muffler diffuser insert adapted to be used with an exhaust system for effectively helping to reduce noise and back pressure attendant to engine operation, and, more particularly, an improved muffler diffuser insert which is virtually free-flowing, but which will not restrict an outgoing exhaust air flow.

A still further advantage of the present invention is to provide an improved muffler diffuser insert that fits into a factory or aftermarket muffler without “plugging up” the muffler and causing back pressure and overheating of the muffler to build.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the present invention is described below with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of an embodiment of the muffler diffuser of the present invention;

FIG. 2 is a top view of the embodiment of the muffler diffuser shown in FIG. 1;

FIG. 3 is a front view of the embodiment of the muffler diffuser shown in FIG. 1, the muffler diffuser being shown in place within a muffler exhaust, and about to be secured thereto with screws tightened by an Allen key; and

FIG. 4 is an exploded cut away view of the muffler diffuser of the present invention in place within a muffler, and which illustrates how sound and exhaust from the muffler are directed through the muffler diffuser to the outside atmosphere.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 broadly illustrates the muffler diffuser insert 1 of the present invention, which essentially comprises a body portion 5 integrally connected to a cap end 3, in a preferred embodiment, or which connection can be accomplished through welding or through other means which would be apparent to a worker skilled in the art. It can also be seen in FIG. 1 that the cap end is perpendicularly positioned in relation to the body portion. Preferably, the body portion 5 is elongated, and is perpendicularly positioned in relation to the cap end 3. As can be seen in FIG. 2, the body portion 5 also defines therein an opening 15, which will be described hereinafter, and possesses an insertion end 9, distally opposed from the cap end 3, which is meant for placement within a muffler. Further, the insertion end 9 further possesses sound deflection portions 7, which are positioned on either side of the outmost point of insertion end 9, such angled portions being placed, preferably, at a 45° angle in relation to the outmost end of the insertion end 9, though again it will be readily apparent that slight modifications or alternative configurations to this could also be utilized, as would be apparent to a worker skilled in the art. The purpose of the sound deflection portions 7 is to deflect sound waves in the exhaust flow and direct them into the packing of the muffler, so as to effect noise reduction of the engine, as will be later hereinafter described.

It should be noted that a thickness of cap end 3 needs to be of adequate thickness so that the muffler diffuser insert of the present invention does not warp, or become fused or lodged in the muffler due to excessive heat from the exhaust gases. It will be readily apparent that this thickness could be varied to a certain degree, as would be apparent to a worker skilled in the art. The cap end 3 also further defines therein a flow exit opening 13, which can be seen with reference to FIGS. 1 and 3. This is the exit portion of the muffler diffuser insert of the present invention which allows for the sound to be reduced but does not restrict the exhaust flow. It will also be understood that a plurality of openings could also be utilized in the cap end, as would be apparent to a worker skilled in the art. In a preferred embodiment, a length of opening 15 is to be greater than three (3) times a diameter of the flow exit opening 13, though it will be readily apparent that slight modifications or alternative configurations to this could also be utilized, as would be apparent to a worker skilled in the art. It will be readily understood that the diameter of the flow exit opening can be varied slightly, depending upon the size of the muffler diffuser used for particular differing brands of mufflers (as different manufacturers use various sizes of internal perforated tubes), provided that the length of opening 15 is also correspondingly varied so as to, preferably, be greater than three (3) times a diameter of the flow exit opening 13.

With reference to FIG. 3, the muffler diffuser of the present invention is fastened to the internal inner construction of the muffler with, in one possibility, screws inserted by allen key set screws 17, though it will be apparent that other variations as to this securement are possible. These screws can be inserted through threaded screw openings 11 in the muffler diffuser, as can be seen with reference to FIGS. 1 and 2. In the example shown in FIG. 3, these two set screws will not allow the silencer to fall out while being operated. Preferably, the hardware (set screws) are manufactured from stainless steel so that they will not corrode or seize in the muffler diffuser, though it will be readily apparent that other similar configurations may be utilized, as would be apparent to a worker skilled in the art. Also, in a preferred embodiment, the muffler diffuser insert of the present invention is manufactured from aluminum, which helps to dissipate heat more readily, and for its particular characteristics, such as resistance to moisture and corrosion, while still remaining lightweight, though it will be readily apparent that other materials may also be utilized, as would be apparent to a worker skilled in the art.

In utilizing the muffler diffuser of the present invention, and with reference to FIG. 4, the muffler diffuser can be inserted and attached into a muffler having an inner perforated tube diameter. In doing do, insertion end 9 is inserted first into the muffler, and, when fully inserted, distally opposed cap end 3 abuts up against the exterior end of the muffler exhaust opening, as can be seen in FIG. 4, and the muffler diffuser is longitudinally mounted and aligned within a longitudinal axis of the muffler. With reference to FIG. 3, the muffler diffuser of the present invention can then be fastened to the internal inner construction of the muffler with screws inserted by allen key set screws 17. With reference again to FIG. 4 for exhaust flow, and starting from the inlet side of the muffler, the exhaust flow 19 exiting the muffler will encounter the insertion end 9 and sound deflection portions 7 of the muffler diffuser, which help to deflect the sound waves from the exhaust flow into the body (packing) of the stock muffler 21. Once the sound has been deflected into the body of the stock muffler the sound decibels will accordingly be reduced.

It is important to note that the exhaust flow 19 will travel the path of least resistance will travel around the sound deflection portions 7, entering into and being neutralized in the opening 15 of the muffler diffuser. At this point, the exhaust flow is then evacuated through the flow exit opening 13 in the cap end 3 of the muffler diffuser. As noted previously, a diameter of this exhaust opening is a calculation that depends on the internal diameter of the factory muffler. The diameter of the hole is a critical factor as this also helps in the scavenging effect on the muffler. For example, at this point the sanctioning body (Motorcycle Industry Council) for motorcycle racing has established that the SAE J1287 JUL98 Noise Testing Procedure requires that all motorcycles operate at a 96 db or less. This measurement is taken from 20″ behind the exhaust centerline on a 45 degree angle. With respect to use of the muffler diffuser of the present invention, and through the muffler diffuser having sound deflection portions 7 and the length of opening 15 being greater than three (3) times a diameter of the exhaust outlet into which the muffler diffuser is placed, decibel levels can usually be reduced anywhere from 4 to 10 dB, through use of this muffler diffuser, and without increasing the exhaust back pressure to a point where it will cause premature engine failure.

The present invention has been described herein with regard to preferred embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein. 

1. A muffler diffuser adapted to be used with and mountable within a muffler comprising: a cap end having at least one exhaust opening defined therein for permitting an exhaust flow from the muffler to pass through, the cap end abutting against an exhaust end of the muffler when the muffler diffuser is mounted within the muffler; a body portion connected to the cap end, the body portion defining therein an opening for permitting the exhaust flow from the muffler to pass through, and having at least one sound deflection portion for use in deflecting sound waves contained in the exhaust flow so as to enhance noise diffusion; and means for securing the muffler diffuser within the muffler.
 2. The muffler diffuser of claim 1, wherein the cap end is of a substantially circular configuration.
 3. The muffler diffuser of claim 2, wherein the body portion of the muffler diffuser is adapted to be longitudinally mounted and aligned within a longitudinal axis of the muffler.
 4. The muffler diffuser of claim 3, wherein the cap end is perpendicularly positioned in relation to the body portion.
 5. The muffler diffuser of any one of claims 1 to 4, wherein the sound waves contained in the exhaust flow are deflected back into the muffler.
 6. The muffler diffuser of claim 1, wherein the cap end possesses a plurality of openings for permitting the exhaust flow from the muffler to pass through.
 7. The muffler diffuser of claim 1, wherein the body portion further comprises at least one screw opening defined in side portions thereof for receiving securing screws, whereby the muffler diffuser can be secured within the muffler.
 8. The muffler diffuser of claim 1, wherein the at least one sound deflection portion is positioned at a 45° angle in relation to an outmost point of the body portion.
 9. The muffler diffuser of claim 1, wherein the opening of the body portion is an elongated opening, which is greater than three times a diameter of the at least one exhaust opening.
 10. A muffler diffuser adapted to be used with and mountable within a muffler comprising: a cap end abutting against an exhaust end of the muffler when the muffler diffuser is mounted within the muffler, the cap end having at least one exhaust opening defined therein for cooperation with the exhaust end of the muffler, so as to permit an exhaust flow from the exhaust end of the muffler to pass through; a body portion connected to the cap end, the body portion defining therein an elongated opening for permitting the exhaust flow from the muffler to pass through, and having at least one sound deflection portion for use in deflecting sound waves contained in the exhaust flow so as to enhance noise diffusion; and means for securing the muffler diffuser within the muffler.
 11. A muffler diffuser adapted to be used with and mountable within a muffler comprising: a cap end abutting against an exhaust end of the muffler when the muffler diffuser is mounted within the muffler, the cap end having at least one exhaust opening defined therein for cooperation with the exhaust end of the muffler, so as to permit an exhaust flow from the exhaust end of the muffler to pass through; a body portion connected to the cap end, the body portion having a distal end portion which comprises an outermost end and two sound deflection portions positioned on either side of the outermost end for use in deflecting sound waves contained in the exhaust flow so as to enhance noise diffusion, the body portion also defining therein an elongated opening which is greater than three times a diameter of the at least one exhaust opening for permitting the exhaust flow from the muffler to pass through; and means for securing the muffler diffuser within the muffler.
 12. The muffler diffuser of claim 10, wherein the cap end is perpendicularly positioned in relation to the body portion.
 13. The muffler diffuser of claim 10, wherein the opening of the body portion is an elongated opening which is greater than three times a diameter of the at least one exhaust opening.
 14. The muffler diffuser of claim 10, wherein the body portion further comprises at least one screw opening defined in side portions thereof for receiving securing screws, whereby the muffler diffuser can be secured within the muffler.
 15. The muffler diffuser of claim 11, wherein the sound deflection portions are positioned at a 45° angle in relation to the outermost end.
 16. The muffler diffuser of claim 10, wherein the cap end possesses a plurality of openings for permitting the exhaust flow from the muffler to pass through.
 17. The muffler diffuser of claim 10, wherein the cap end is of a substantially circular configuration.
 18. The muffler diffuser of claim 10, wherein the body portion of the muffler diffuser is adapted to be longitudinally mounted and aligned within a longitudinal axis of the muffler. 